Mist Dispersal System for Air Conditioners

ABSTRACT

An apparatus for increasing the efficiency of air conditioning units, and methods of improving the efficiency of the air cooling function in air conditioners is disclosed by dispersing a water or vapor mist onto the heat transfer coils of a condenser used in an air cooling unit to effectively and efficiently reduce the use of power by the condenser and reduce the time the condenser must run. The apparatus includes fluid lines and a filter, the function of which is to remove particulate matter from the fluid, prevent scale formation, and provide a coating on the surface of certain parts of the condenser. The filter is configured to stop the flow of fluid when the filter can no longer provide these functions.

PRIORITY STATEMENT

This application claims the benefit of U.S. Provisional Application No. 61/209,946, filed Mar. 12, 2009.

FIELD OF THE INVENTION

This invention relates to highly efficient air conditioning units; and more specifically, to a method of improving the efficiency of the air cooling function in air conditioners by dispersing a water or vapor mist onto the condensers of air cooling units effectively and efficiently thereby reducing the use of power by the condenser and reducing the time the condenser must run.

The present invention further comprises an in-line filter for removing particulate matter from the fluid, sequestering dissolved solids in the hard water to prevent the formation of scale on the condenser and providing a coating on the surface of the condenser to prevent corrosion. The filter is configured to stop the transfer of fluid when the filter has run its useful life and is no longer providing all of these functions.

BACKGROUND OF THE INVENTION

Air cooling is used in refrigeration units and air conditioners to lower the temperature of small spaces, such as the inside of the refrigerator, and large spaces, such as rooms, homes, apartment buildings, office buildings, and industrial buildings. These air cooling systems are generally inefficient because of the significant amount of energy necessary to cool a large amount of air, which results in a shorter life span of the cooling systems, greater energy consumption, increased levels of pollution, and high operating costs.

Generally, air cooling, sometimes known as air conditioning, units are comprised of a closed refrigerant loop, forming a heat pump that includes a compressor, condenser, expansion valve and evaporator. Although there are numerous types of compressors, compressors are mechanical devices that increase the pressure of a gas by reducing its volume. The compressor provides both the motive force to move the refrigerant through the closed loop system and the required thermodynamic state of the refrigerant as it is passed to the condenser. A condenser is a heat exchanger that condenses a substance from its gaseous to its liquid state thereby giving up the substance's heat which is transferred from the refrigerant, such as Freon, to the heat transfer fins of the condenser coil. In order to aid in the transfer of heat away from the condenser fins, the condenser uses a device such as a fan that moves air over the condenser coils, cooling them by convective heat transfer. Next, the liquid refrigerant passes through a throttling device known as an expansion valve, which sets the proper thermodynamic conditions on the way to the evaporator. The evaporator converts the mainly liquid refrigerant mixture into a vapor, absorbing heat from the heat transfer fins of the evaporator. The evaporator employs a fan or blower to move air through the evaporator coils and thus cools the air. The gaseous refrigerant is then passed to the compressor to begin the cycle again.

Applying a mist to the condenser coils improves the heat transfer from the condenser to the external environment or hot side of the heat pump system. This improved heat transfer has the effect of reducing the power required by the compressor and reducing the operating time of the air conditioner or heat pump system. With efficient application of the mist, the air conditioner will run for a shorter period of time and will not have to work as hard. The decrease in demand on the compressor unit will lead to a longer life as well as saving money, energy, and unnecessary pollution.

The currently available methods of applying mist to a condenser are lacking in certain areas; with each containing certain inefficiencies and disadvantageous aspects. For example, U.S. Pat. No. 6,105,376 discloses a vane paddle member controlling the spray of the mist onto the condenser. The force of air output from the condenser drives the movement of the vane paddle, which in turn initiates the spray of mist over the condenser. Similarly, U.S. Pat. No. 5,605,052 discloses a spray mist system positioned around a condenser that is activated by a paddle that detects air output from the fan over the condenser. These two mist application methods are limited by the fact that the paddle actuators block part of the condenser's airflow, which reduces the potential energy saving as a result of applying the mist.

U.S. Pat. No. 5,419,147 teaches the use of a multiple sided tube with interspersed sprayers. The sprayers are regulated by an electrical on-off solenoid switch connected to a thermostat, which synchronizes the mist sprays with the operation of the condenser, requiring a large amount of energy and an independent source of electrical power.

U.S. Pat. No. 5,285,651 teaches a mister spray unit that sprays from the sides and top of the unit with a shield, trough and drain to capture excess water. This method also requires a paddle that restricts condenser airflow.

U.S. Pat. No. 6,837,065 teaches the use of a mist sprayer to cool air surrounding the condenser and additionally using a mist sprayer to cool the air near the air intake of the cooling unit. Thus, an inefficient two sprayer systems would be running at the same time.

The prior art inventions require a high level of energy, have insufficient mist sprayer positions, an inadequate method of keeping the pipes unblocked, and/or have other disadvantages. The presently disclosed invention improves upon the existing technology.

SUMMARY OF THE INVENTION

The general principles of the invention are embodied in an apparatus to be retrofitted on a condenser unit of an air conditioner. Although the preferred embodiment is for a retrofit application, the system can be designed and built to attach to a new air conditioner condenser and still be within the scope of the present invention.

The preferred embodiment includes fluid supply lines extending to one or more fluid distribution lines. The fluid distribution lines may extend directly from the fluid supply line or interface through a distribution manifold. The flow of the fluid supply line from a fluid source (e.g. garden hose or residential water spout) is blocked by a valve that can be switched to open the flow by electrical energy produced by a turbine and generator placed within the condenser fan air flow.

The valve may be electrically actuated as in the case of the preferred embodiment or actuated directly by a mechanism, which transfers aerodynamic force to open the valve.

As described in the examples herein, direct actuation of the valve by the condenser fan airflow may be accomplished by a number of methods. The dynamic pressure differential of the condenser fan airflow may be ported directly to an air piloted valve to actuate flow to the misting nozzles. Alternatively, an aerodynamic structure such as an air-foil may be mechanically coupled to directly actuate the valve. Such an aerodynamic shape will improve on prior art by minimizing the blockage of the condenser fan airflow.

In the case of an electrically actuated valve, the valve may be a direct acting solenoid valve or a bi-stable (latching) solenoid valve. In the case of a direct acting solenoid, the valve has only one stable state and remains open only when electrically energized. A direct acting solenoid valve provides an inherent fail-safe feature since the valve will automatically close when the electrical supply is interrupted.

In the case of a bi-stable or latching solenoid valve, the valve only requires electrical energy to change states between the open and closed position, but requires no electrical energy to remain in either the open or closed position. A bi-stable or latching valve has the advantage of using the minimum amount of electrical energy for device operation. A bi-stable or latching valve requires a fail-safe provision in the electrical supply circuit to ensure that the valve closes in situations where a loss of power has occurred. This fail-safe feature may be accomplished by a capacitor that is charged before the valve opens and then discharges energy to close the valve if a loss of power occurs.

The distribution lines lead to sprayer features that disperse mist over the condenser's heat transfer coils. In the preferred embodiment, the distribution line(s) and fluid supply lines contain in-line combination particulate and poly-phosphate filter to prevent valve clogging, scale deposits, and inhibit corrosion of condenser parts, thus maintaining the full potential for fluid flow therein. The filter housing is provided with a feature that prevents fluid flow when the charge of polyphosphate crystals has been consumed. This ensures that the polyphosphate filter is replaced preventing unwanted scale deposits or corrosion when filter device use continues after depletion of the polyphosphate crystals.

In another embodiment, the sprayer features include misting nozzles mounted within decorative structures, possibly at several locations on the distribution and fluid supply lines. The sprayers may have integral features (decorative or not) that assist in the dispersion of mist by rotating under the force of the water supply pressure. Such a rotating feature would cause the sprayer nozzle(s) to rotate through a circular path increasing the area of mist application and thus the overall effectiveness of the misting process.

In alternative embodiments, the fluid pressure and flow rate may be controlled by an additional metering valve, which may be set by the user (manual), or automatically set (electronic), based on factors such as local climate and available supply water pressure.

The valve mechanism(s) could be powered by a variety of power sources, inter alia, power from the condenser unit by either direct connection or inductive coupling, power from the building by either direct connection or inductive coupling, power generated by the air output of the condenser using a small air turbine and generator, photovoltaic panel, a Peltier thermoelectric device utilizing air to ground, or condenser to air temperature gradients, a replaceable battery or any combination thereof. Other sources can be used to apply power as understood by one having ordinary skill in the art.

An embodiment may also contain an energy storage device for operations, regulation or fail-safe purposes using rechargeable batteries, capacitors or a combination of both. The embodiments utilizing an electrically actuated valve and microprocessor or microcontroller could optimize misting conditions through logical algorithms and data obtained by a combination of sensors, inter alia, sensors for humidity, temperature, wind speed, localized moisture and solar radiance. Such optimization may also use signal conditioning circuitry, a central processing unit, such as a microprocessor or microcontroller, fluid metering device or condenser fan operation sensors, dynamic pressure based airflow sensor, or thermally conductive airflow sensor, among others. These sensors could also collect, store, receive, and/or send valuable functional efficiency information regarding the operation of the mist dispersal system and transmit environmental information.

One or more of the disclosed embodiments may require a condenser fan operation sensor to detect and signal the control electronics when the condenser fan begins to operate. Sensors for this purpose may include, but are not limited to, pressure sensors that detect the dynamic pressure of airflow around or over the condenser, vibration sensors, acoustic sensors, temperature sensors in the condenser fan airflow, temperature sensors in intimate contact with the coolant supply line, temperature sensors in intimate contact with the coolant return line, inductive sensors that detect the flow of electrical current to the condenser fan or compressor, voltage sensors that detect the application of electrical potential to the condenser fan or compressor, optical sensors that detect the motion of the condenser fan blades and sensors that detect residual electro-magnetic interference generated by the condenser fan or compressor, among others.

Another embodiment may include an LED or other indicator to give feedback to the user regarding the need to maintain the unit or replace any consumables such as the polyphosphate filter. Such visual indications displayed by the system may be based on, inter alia, internal algorithms that total product usage time or by sensing the state or performance of specific components or processes. Further, the fluid flow prevention described herein can be monitored for a reduction or stoppage of fluid flow and indicated as feedback to the user.

Any of the embodiments may include festive or decorative shaped attachments. The fluid supply lines and fluid distribution lines integral in the system may be formed into festive or decorative shapes or colors also. In particular, the mist sprayers and distribution lines may be mounted to decorative vertical posts that are pressed into the soil around the condenser and provide a location for mist application that is detached from the condenser. The decorative features can also be in the form of one or more artificial rocks positioned around the air conditioning condenser, connected to the main fluid supply line, and containing various components like the electronic controller, battery power supply and electronically controlled valve. Additional artificial rocks could function as slave units, connected by fluid distribution lines and containing integral misting nozzles that apply the water mist to the coils of the air conditioning condenser.

Mist sprayers may also be mounted to the face of the condenser directly. The fluid supply lines and fluid distribution lines may also form an independent frame around the condenser. Alternatively, the system could be attached to the condenser at certain points to ensure stability. The attachment method could include, inter alia, magnetic force, adhesive, screw, nail, clamp, bolt, tack, or any other process that allows a mist sprayer nozzle to provide the necessary fluid mist into the condenser unit at the correct location.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a mist dispersal system in accordance with the present invention;

FIG. 2A is a perspective view of a mist dispersal system in accordance with the present invention;

FIG. 2B is a section view of an in-line filter with a sealing feature, in accordance with the present invention;

FIG. 3A is a top-down view of a mist dispersal system in accordance with the present invention;

FIG. 3B is a side view of a mist dispersal system in accordance with the present invention;

FIG. 4A is a side view of a mist sprayer nozzle in accordance with the present invention; and

FIG. 4B is front view of a mist sprayer nozzle in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows an embodiment of the present invention improving on prior art systems that apply water or mist to a condenser by utilizing a mist dispersal system 10 for dispersing a water or vapor mist over a condenser unit 12. As described herein, dispersing water or vapor mist onto the condenser of an air cooling unit, improves the efficiency of the air cooling function in air conditioners. The present invention provides a novel apparatus and method for increasing the efficiency of the air conditioner.

FIG. 2A shows the mist dispersal system 10 of the present invention which includes a number of components, including the system's main filter 110. In the preferred embodiment the filter 110 is an in-line particulate filter such as a polyphosphate crystal filter 110, although other types of filters may be used. The system's filter 110, which can also serve as a coupling attachment, is shown as containing a garden hose fitting 112. This is the point of connection to a fluid source (e.g., a garden hose, water spout or faucet). The distal end 114 of the polyphosphate and particulate filter 110 screws onto a standard garden hose fitting. The proximal end 116 of the filter 110 is secured to a fluid supply line 120.

FIG. 2B shows a cross-section of the polyphosphate filter 110 in accordance with the present invention. The filter 110 has an internal charge of polyphosphate crystals 118 and movable sealing plug 122. The polyphosphate crystals 118 dissolve in the fluid to create a coating that is applied during mist dispersal to the various parts of the condenser, including the heat transfer coils. The flow of water from inlet 114 to outlet 116 within the polyphosphate filter 110 gradually dissolves the polyphosphate crystals 118 throughout the useful life of the filter 110. The sealing plug 122 is held against the polyphosphate crystal charge 118 by the force of the fluid flow during normal operation. Narrow grooves around the sealing plug 122 allow water to bypass the plug 122 during normal operation while polyphosphate crystals 118 remain within the filter housing 124. When the polyphosphate crystals 118 have completely dissolved, the force of the fluid flow will push the sealing plug 122 against the downstream bulkhead 126 of the filter 110 and cause a seal between the flat face 128 of the plug 122 and the flat face 138 of the bulkhead 122 thus preventing any further supply water flow. This functionality of the filter 110 prevents any further use of the filter 110 until a replacement filter is installed and therefore prevents any scale build-up or corrosion on the condenser unit.

In the preferred embodiment, the user turns the fluid source on, and the fluid in the fluid supply line 120 is first interrupted by a valve (not shown) contained within the turbine housing. A microcontroller (not shown) that is also contained within the turbine housing switches the valve using power supplied by the turbine 130 as shown in FIGS. 3A and 3B. The turbine 130 is positioned in the path of the output air of the condenser unit 12 with minimum airflow blockage. Sufficient force from the airflow causes the blades 132 of the turbine 130 to rotate and supply power to the internal electronics. The internal electronics cause the valve to open up the fluid supply line 120 and allow fluid to flow past the valve.

As shown in FIGS. 3A and 3B, the turbine 130 is located in a turbine casing unit 134, having a top element 134 a and a bottom element 134 b such that the elements 134 a, 134 b can be separated and the turbine 130, valve and electronics can be accessed for easy maintenance, cleaning or repair. The turbine casing unit 134 secures the turbine 130 to the condenser top surface with a connection element 136. The connection element 136 is known by a person having ordinary skill in the art and could include one or more of the following devices, either alone or in combination: a screw, nail, bolt, clamp, elastic, adhesive, magnet, etc. The fluid supply line and fluid distribution lines are secured to the turbine housing 134 a by a push fitting, hose barb fitting, compression fitting, threaded fitting or a combination of these or other devices.

In an alternative embodiment, the turbine power source may be substituted with another source of power such as a photovoltaic panel, direct connection or inductively coupled with the condenser power supply or building power, a Pelteir thermoelectric device or a battery. Since the turbine also serves as a condenser fan operation sensor, these alternate power sources may require an independent method of sensing the operation of the condenser fan.

Sensors for this purpose may include, but are not limited to, pressure sensors that detect the dynamic pressure of airflow around or over the condenser, vibration sensors, acoustic sensors, temperature sensors in the condenser fan airflow, temperature sensors in intimate contact with the coolant supply line, temperature sensors in intimate contact with the coolant return line, inductive sensors that detect the flow of electrical current to the condenser fan or compressor, voltage sensors that detect the application of electrical potential to the condenser fan or compressor, optical sensors that detect the motion of the condenser fan blades and sensors that detect residual electro-magnetic interference generated by the condenser fan or compressor.

Once the valve is in the open position, the fluid will flow through the fluid supply line until it reaches the second end 124 of the fluid supply line, shown in FIG. 2A. Then, the fluid will start to rise in the fluid distribution lines 140. There are mist sprayer nozzles 150 interspersed on the fluid distribution lines 140. The mist sprayer nozzles 150 are shown in more detail in FIGS. 4A and 4B. The fluid spout 152 of the mist sprayer nozzle 150 is surrounded by a casing 154 that protrudes at least slightly. This protrusion acts to direct the mist away from the spout and onto the condenser unit 12, with the mist landing on the condenser coils.

The preferred embodiment utilized various decorative features, including shapes that mimic flower petals 156. Further, to the extent possible, the preferred embodiment of the present invention utilizes artificial rocks and imitation outdoor elements to hide the various components of the present invention. The decorative features are in the form of one or more artificial rocks positioned around the air conditioning condenser. The first of the artificial rocks connected to the main fluid supply line could contain internally an electronic controller, battery power supply and electronically controlled valve. One or more additional artificial rocks could function as slave units, connected by fluid distribution lines and containing integral misting nozzles that apply the water mist to the coils of the air conditioning condenser.

The mist applied to the condenser coils act to cool the condenser coils and decrease the necessary run time of the condenser, and the power required to operate the air conditioning system overall. This efficient system improves the compressor lifetime and helps the overall system work more efficiently.

With respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed in the current invention.

The foregoing invention is illustrative only of the principles of the invention. Since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the show and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. 

1. A mist dispersal system for dispersing a mist onto a condenser's heat transfer coils, comprising: a) a fluid supply line, said fluid supply line being capable of transferring a fluid from a fluid source; b) at least one fluid distribution line, said at least one fluid distribution line being capable of transferring said fluid; c) A filter, said filter being positioned for allowing fluid to transfer throughout the mist dispersal system, said filter functioning to provide a coating for said condenser's heat transfer coils from said fluid, said filter configured to stop the transfer of fluid when said filter can no longer provide said coating; d) a distribution manifold, said distribution manifold configured to select one of the at least one fluid distribution line to receive fluid; e) a valve, said valve being capable of actuation to periodically block the fluid from traveling to said at least one distribution line, wherein actuation of said valve may be controlled; f) at least one mist sprayer; said at least one mist sprayer connected to said at least one distribution line and configured to receive fluid from said at least one distribution line, said at least one mist sprayer located to disperse a mist over the condenser's heat transfer coils, thereby increasing the efficiency of the air cooling unit.
 2. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 1, wherein said at least one fluid supply line is a garden hose.
 3. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 1, wherein said valve can be actuated to allow the transfer of fluid using electrical energy produced by a turbine and generator placed within the condenser fan airflow.
 4. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 1, wherein said valve can be actuated to allow the transfer of fluid electrically to open the valve.
 5. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 1, wherein said valve can be actuated to allow the transfer of fluid by a mechanism that transfers aerodynamic force to open the valve.
 6. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 1, wherein said valve can be actuated to allow the transfer of fluid using a dynamic pressure differential of the condenser fan airflow ported directly to an air piloted valve to actuate flow.
 7. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 1, wherein said at least one mist sprayer has integral features that assist in dispersing mist by rotating under the force of the water supply pressure, thereby causing the sprayer to rotate through a circular path to increase the area of mist application.
 8. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 1, wherein said filter comprises particulate to prevent valve clogging, scale deposits, and inhibit corrosion of condenser parts, thereby increasing the amount of mist dispersal for the greatest amount of time.
 9. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 8, wherein said filter further comprises a self-sealing plug designed to prevent fluid flow through the filter once all of the particulate has been dissolved.
 10. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 9, wherein said particulate is polyphosphate crystals.
 11. The mist dispersal system for dispersing a mist onto a condenser's heat transfer coils of claim 9, wherein said self-sealing plug moves closer to the distal end of the filter as particulate dissolves. 